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Abstract:

Expandable reamers comprise a housing and at least one blade supported by
the housing. The at least one blade is movable between an extended
position and a retracted position. The at least one blade is in the
retracted position when a travel sleeve is in a first sleeve position and
a trigger sleeve is in an unobstructed position. The at least one blade
is movable to the extended position when the travel sleeve is in a second
sleeve position and the trigger sleeve is in the unobstructed position.
The at least one blade is in the retracted position when the travel
sleeve is in the second sleeve position and the trigger sleeve is in an
obstructed position.

Claims:

1. An expandable reamer for use in a borehole in a subterranean
formation, comprising: a housing defining an internal bore; at least one
blade supported by the housing, the at least one blade being movable
between an extended position and a retracted position; a travel sleeve
located within the internal bore and detachably connected to the housing,
the travel sleeve defining an internal flow path and comprising a first
obstruction engagement, at least one first port at a first longitudinal
position, and at least one second port at a second, upper longitudinal
position, wherein the travel sleeve is located in a first sleeve position
when connected to the housing and is movable from the first sleeve
position to a second, different sleeve position when disconnected from
the housing; and a trigger sleeve located within the internal flow path
and detachably connected to the travel sleeve, the trigger sleeve
defining an internal flow bore and comprising a second obstruction
engagement, wherein the trigger sleeve is located in an unobstructed
position when connected to the travel sleeve and is movable from the
unobstructed position to an obstructed position when disconnected from
the travel sleeve, wherein the at least one blade is in the retracted
position when the travel sleeve is in the first sleeve position and the
trigger sleeve is in the unobstructed position, the at least one blade is
movable to the extended position when the travel sleeve is in the second
sleeve position and the trigger sleeve is in the unobstructed position,
and the at least one blade is in the retracted position when the travel
sleeve is in the second sleeve position and the trigger sleeve is in the
obstructed position.

2. The expandable reamer of claim 1, wherein the trigger sleeve further
comprises at least one trigger port and wherein the at least one trigger
port is at least substantially aligned with the at least one second port
when the trigger sleeve is in the unobstructed position.

3. The expandable reamer of claim 2, wherein the at least one trigger
port is at least substantially aligned with the at least one first port
when the trigger sleeve is in the obstructed position.

4. The expandable reamer of claim 1, wherein the trigger sleeve further
comprises a sidewall and wherein the sidewall obstructs the at least one
second port when the trigger sleeve is in the obstructed position.

5. The expandable reamer of claim 1, further comprising at least one
sealing member interposed between the housing and the travel sleeve to
form a seal between the housing and the travel sleeve and wherein the at
least one first port is located on a first side of the at least one
sealing member when the travel sleeve is in the first sleeve position and
is located on a second, opposing side of the at least one sealing member
when the travel sleeve is in the second sleeve position.

6. The expandable reamer of claim 1, wherein the travel sleeve is
configured to disconnect from the housing when a first obstruction is
engaged with the first obstruction engagement.

7. The expandable reamer of claim 6, wherein the trigger sleeve is
configured to disconnect from the travel sleeve when a second obstruction
is engaged with the first obstruction engagement.

8. The expandable reamer of claim 1, wherein the first obstruction
engagement is positioned longitudinally below the trigger sleeve.

9. The expandable reamer of claim 8, wherein the first obstruction
engagement comprises a first inner diameter and the second obstruction
engagement comprises a second, greater inner diameter.

10. The expandable reamer of claim 1, further comprising locking dogs
configured to retain the at least one blade in the retracted position
when the travel sleeve is in the first longitudinal position and to
release the at least one blade when the travel sleeve is in the second
sleeve position.

11. The expandable reamer of claim 1, wherein the at least one blade is
biased toward the refracted position.

12. A method of using an expandable reamer in a borehole, comprising:
flowing a drilling fluid through an internal bore defined by a housing,
through an internal flow path defined by a travel sleeve located within
the internal bore and detachably connected to the housing, and through an
internal flow bore defined by a trigger sleeve located within the
internal flow path and detachably connected to the travel sleeve;
releasing a first obstruction into the internal bore to engage with a
first obstruction engagement of the travel sleeve; disconnecting the
travel sleeve from the housing and allowing the travel sleeve to move
from a first sleeve position to a second, different sleeve position when
the first obstruction is engaged with the first obstruction engagement;
extending at least one blade supported by the housing from a refracted
position to an extended position in response to movement of the travel
sleeve from the first sleeve position to the second sleeve position;
releasing a second obstruction into the internal bore to engage with a
second obstruction engagement of the trigger sleeve; disconnecting the
trigger sleeve from the travel sleeve and allowing the trigger sleeve to
move from an unobstructed position to an obstructed position; redirecting
flow of the drilling fluid from the at least one second port through the
internal flow path; and allowing the at least one blade to retract from
the extended position to the refracted position in response to the
redirected flow of the drilling fluid.

13. The method of claim 12, wherein allowing the trigger sleeve to move
from the unobstructed position to the obstructed position comprises
allowing the trigger sleeve to move from an unobstructed position wherein
at least one trigger port of the trigger sleeve is at least substantially
aligned with at least one second port of the travel sleeve to an
obstructed position wherein a sidewall of the trigger sleeve obstructs
the at least one second port.

14. The method of claim 12, wherein redirecting flow of the drilling
fluid from the at least one second port comprises obstructing the at
least one second port with a sidewall of the trigger sleeve.

15. The method of claim 12, wherein allowing the travel sleeve to move
from the first sleeve position to the second, different sleeve position
comprises allowing at least one first port of the travel sleeve to move
from a first side of at least one sealing member interposed between the
housing and the travel sleeve to a second, opposing side of the at least
one sealing member.

16. The method of claim 15, wherein allowing the trigger sleeve to move
from the unobstructed position to the obstructed position comprises
allowing the at least one trigger port to at least substantially align
with the at least one first port of the travel sleeve.

17. The method of claim 12, wherein releasing the second obstruction
comprises releasing a second obstruction having a second outer diameter
larger than a first outer diameter of the first obstruction.

18. The method of claim 12, wherein allowing the travel sleeve to move
from the first sleeve position to the second, different sleeve position
comprises releasing locking dogs configured to retain the at least one
blade in the refracted position in response to movement of the travel
sleeve from the first sleeve position to the second sleeve position.

19. The method of claim 12, further comprising: decreasing a pressure of
the drilling fluid flowing through the internal bore while the travel
sleeve is in the second sleeve position and the trigger sleeve is in the
unobstructed position; allowing the at least one blade to retract to the
refracted position in response to the decrease in the pressure;
increasing the pressure of the drilling fluid; and extending the at least
one blade to the extended position in response to the increase in the
pressure.

20. The method of claim 12, wherein allowing the at least one blade to
retract from the extended position to the refracted position when the
travel sleeve is in the second sleeve position and the trigger sleeve is
in the obstructed position comprises allowing the at least one blade to
retract to the refracted position for at least as long as the expandable
reamer remains in the borehole.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent
Application Ser. No. 61/619,869, filed Apr. 3, 2012, the disclosure of
which is incorporated herein in its entirety by this reference. The
subject matter of the present application is related to the subject
matter disclosed in U.S. patent application Ser. No. 13/327,373 filed
Dec. 15, 2011, to Radford et al., the disclosure of which is incorporated
herein in its entirety by this reference.

FIELD

[0002] The disclosure relates generally to expandable reamers for use in
boreholes in subterranean formations and methods of using such expandable
reamers. More specifically, disclosed embodiments relate to expandable
reamers that selectively extend and retract blades.

BACKGROUND

[0003] Expandable reamers are generally employed for enlarging boreholes
in subterranean formations. In drilling oil, gas, and geothermal wells,
casing is usually installed and cemented to prevent the walls of the
borehole from caving in while providing requisite shoring for subsequent
drilling to greater depths. Casing is also installed to isolate different
formations, to prevent cross flow of formation fluids, and to enable
control of formation fluids and pressure as the borehole is drilled. To
increase the depth of a previously drilled borehole, new casing is laid
within and extended below the original casing. The diameter of any
subsequent sections of the well may be reduced because the drill bit and
any further casing must pass through the original casing. Such reductions
in the borehole diameter may limit the production flow rate of oil and
gas through the borehole. Accordingly, a borehole may be enlarged in
diameter when installing additional casing to enable better production
flow rates of hydrocarbons through the borehole.

[0004] One approach used to enlarge a borehole involves employing an
extended bottom-hole assembly with a pilot drill bit at the end and a
reamer assembly some distance above the pilot drill bit. This arrangement
permits the use of any standard rotary drill bit type (e.g., a rolling
cone bit or a fixed cutter bit), as the pilot bit and the extended nature
of the assembly permit greater flexibility when passing through tight
spots in the borehole as well as the ability to stabilize the pilot drill
bit so that the pilot drill bit and the following reamer will traverse
the path intended for the borehole. This aspect of an extended
bottom-hole assembly is particularly significant in directional drilling.
Expandable reamers are disclosed in, for example, U.S. Pat. No. 7,900,717
issued Mar. 8, 2011, to Radford et al.; U.S. Pat. No. 8,028,767 issued
Oct. 4, 2011, to Radford et al.; and U.S. Patent Application Pub. No.
2011/0073371 published Mar. 31, 2011, to Radford, the disclosure of each
of which is incorporated herein in its entirety by this reference. The
blades in such expandable reamers are initially refracted to permit the
tool to be run through the borehole on a drill string, and, once the tool
has passed beyond the end of the casing, the blades are extended so the
bore diameter may be increased below the casing.

BRIEF SUMMARY

[0005] In some embodiments, expandable reamers for use in boreholes in
subterranean formations comprise a housing defining an internal bore. At
least one blade is supported by the housing. The at least one blade is
movable between an extended position and a retracted position. A travel
sleeve is located within the internal bore and detachably connected to
the housing. The travel sleeve defines an internal flow path and
comprises a first obstruction engagement, at least one first port at a
first longitudinal position, and at least one second port at a second,
upper longitudinal position. The travel sleeve is located in a first
sleeve position when connected to the housing and is movable from the
first sleeve position to a second, different sleeve position when
disconnected from the housing. A trigger sleeve is located within the
internal flow path and detachably connected to the travel sleeve. The
trigger sleeve defines an internal flow bore and comprises a sidewall, a
second obstruction engagement, and at least one trigger port. The trigger
sleeve is located in an unobstructed position when connected to the
travel sleeve and is movable from the unobstructed position to an
obstructed position when disconnected from the travel sleeve. The at
least one trigger port is at least substantially aligned with the at
least one second port when the trigger sleeve is in the unobstructed
position and the sidewall obstructs the at least one second port when the
trigger sleeve is in the obstructed position. The at least one blade is
in the retracted position when the travel sleeve is in the first sleeve
position and the trigger sleeve is in the unobstructed position. The at
least one blade is movable to the extended position when the travel
sleeve is in the second sleeve position and the trigger sleeve is in the
unobstructed position. The at least one blade is in the retracted
position when the travel sleeve is in the second sleeve position and the
trigger sleeve is in the obstructed position.

[0006] In other embodiments, methods of using expandable reamers in
boreholes comprise flowing a drilling fluid through an internal bore
defined by a housing, through an internal flow path defined by a travel
sleeve located within the internal bore and detachably connected to the
housing, and through an internal flow bore defined by a trigger sleeve
located within the internal flow path and detachably connected to the
travel sleeve. A first obstruction is released into the internal bore to
engage with a first obstruction engagement of the travel sleeve. The
travel sleeve is disconnected from the housing and the travel sleeve is
allowed to move from a first sleeve position to a second, lower sleeve
position when the first obstruction is engaged with the first obstruction
engagement. At least one blade supported by the housing is extended from
a retracted position to an extended position in response to movement of
the travel sleeve from the first sleeve position to the second sleeve
position. A second obstruction is released into the internal bore to
engage with a second obstruction engagement of the trigger sleeve. The
trigger sleeve is disconnected from the travel sleeve and the trigger
sleeve is allowed to move from an unobstructed position wherein at least
one trigger port of the trigger sleeve is at least substantially aligned
with at least one second port of the travel sleeve to an obstructed
position wherein a sidewall of the trigger sleeve obstructs the at least
one second port. Flow of the drilling fluid is redirected from the at
least one second port through the internal flow path. The at least one
blade is allowed to retract from the extended position to the retracted
position in response to the redirected flow of the drilling fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] While the specification concludes with claims particularly pointing
out and distinctly claiming what are regarded as embodiments of the
invention, various features and advantages of disclosed embodiments may
be more readily ascertained from the following description when read in
conjunction with the accompanying drawings, in which:

[0008] FIG. 1 is a perspective view of an expandable reamer;

[0009]FIG. 2 is a cross-sectional view of the expandable reamer of FIG. 1
in a first operational state;

[0010]FIG. 3 is a cross-sectional view of the expandable reamer of FIG. 1
in a second operational state; and

[0011]FIG. 4 is a cross-sectional view of the expandable reamer of FIG. 1
in a third operational state.

DETAILED DESCRIPTION

[0012] The illustrations presented herein are not meant to be actual views
of any particular expandable reamer or component thereof, but are merely
idealized representations employed to describe illustrative embodiments.
Thus, the drawings are not necessarily to scale. Additionally, elements
common between figures may retain the same or similar numerical
designation.

[0013] Disclosed embodiments relate generally to apparatuses expandable
reamers, which selectively extend and retract blades. More specifically,
disclosed are expandable reamers, which, for example, may be locked in a
retracted position during placement into a borehole, may be selectively
actuated between an extended position and a retracted position during
drilling, and may be selectively returned to the retracted position
during removal from the borehole.

[0014] As used herein, the terms "upper," "lower," "below," and "above"
indicate relative positions of an earth-boring tool when positioned for
normal use in a vertical borehole, and are not intended to limit the use
of such an earth-boring tool to vertical or near-vertical drilling
applications.

[0015] As used herein, the term "drilling fluid" means and includes any
fluid that is directed down a drill string during drilling of a
subterranean formation. For example, drilling fluids include liquids,
gases, combinations of liquids and gases, fluids with solids in
suspension with the fluids, oil-based fluids, water-based fluids,
air-based fluids, and muds.

[0016] Referring to FIG. 1, a perspective view of an expandable reamer 100
is shown. The expandable reamer 100 includes a housing 102 comprising a
generally cylindrical structure defining an internal bore 104 through
which drilling fluid may flow and having a longitudinal axis L (e.g., a
central axis within the internal bore 104). The housing 102 may be
configured to connect to other sections of a drill string. For example,
an upper end 106 of the housing 102 may comprise a first connector 108
(e.g., a box connection) and a lower end 110 of the housing may comprise
a second connector 112 (e.g., a pin connection), each of which may be
connected to other components in the drill string, such as, for example,
sections of drill pipe, sections of casing, sections of liner,
stabilizers, downhole motors, pilot drill bits, drill collars, etc. The
housing 102 may support at least one blade 114, to which cutting elements
may be secured, configured to engage with and remove material from a wall
of a borehole. Each blade 114 may be movable between a retracted
position, as shown in FIGS. 1, 2, and 4, in which each blade 114 is
positioned not to engage with the wall of the borehole (though some
incidental contact may occur) and an extended position, as shown in FIG.
3, in which each blade 114 is positioned to engage with the wall of the
borehole.

[0017] The expandable reamer 100 may optionally include stabilizers 116
extending radially outwardly from the housing 102. Such stabilizers 116
may center the expandable reamer 100 in the borehole while tripping into
position through a casing or liner string and while reaming the borehole
by contacting and sliding against the wall of the borehole. In other
embodiments, the expandable reamer 100 may lack such stabilizers 116.

[0018] Referring to FIG. 2, a cross-sectional view of the expandable
reamer 100 of FIG. 1 is shown in a first operational state (e.g., a first
mode of operation). Such a first operational state may correspond to a
pre-actuation, initial, retracted state, and may reflect a state of the
expandable reamer 100 when tripping into a borehole. The expandable
reamer 100 may comprise an actuation mechanism configured to selectively
position the blades 114 in their retracted and extended positions.

[0019] The actuation mechanism may include a travel sleeve 118 located
within the internal bore 104 and detachably connected to the housing 102.
For example, the travel sleeve 118 may be connected to the housing using
detachable hardware 120A, which may comprise, for example, shear screws,
shear pins, exploding bolts, or locking dogs. The travel sleeve 118 may
comprise a generally cylindrical structure defining an internal flow path
122 through which drilling fluid may flow and may comprise a first
obstruction engagement 124. The first obstruction engagement 124 may
comprise, for example, a ball seat, a ball trap, a solid seat, an
expandable seat, or other obstruction engagements known in the art, and
may be configured to engage with a first obstruction 152 (see FIGS. 3 and
4) to actuate the actuation mechanism. The travel sleeve 118 may comprise
at least one first port 126 at a first longitudinal position LP1
through which drilling fluid may flow from the internal flow path 122 to
the internal bore 104 or vice versa. For example, the travel sleeve 118
may include multiple first ports 126 proximate a lower end 128 of the
travel sleeve 118. The travel sleeve 118 may comprise at least one second
port 130 at a second, different longitudinal position LP2 through
which drilling fluid may flow from the internal flow path 122 to the
internal bore 104 or vice versa. For example, the travel sleeve 118 may
include multiple second ports 130 located at a second, upper longitudinal
position LP2, as compared to a first, lower longitudinal position
LP1 of the first ports 126.

[0020] The travel sleeve 118 may be configured to move relative to the
housing 102 when disconnected from the housing 102. For example, the
travel sleeve 118 may be in a first sleeve position when connected to the
housing 102, as shown in FIG. 2, in the first operational state. The
travel sleeve 118 may move to a second, different sleeve position when
disconnected from the housing 102, as shown in FIGS. 3 and 4, in
subsequent states of the expandable reamer 100.

[0021] The expandable reamer 100 may include at least one sealing member
132 interposed between the housing 102 and the travel sleeve 118 to form
a seal 134 between the housing 102 and the travel sleeve 118. For
example, a plurality of sealing members 132 may be interposed between the
housing 102 and the travel sleeve 118 proximate the lower end 128 of the
travel sleeve 118, forming a seal 134 between the housing 102 and the
travel sleeve 118. The sealing members 132 may comprise, for example,
o-rings, omni-directional sealing rings (i.e., sealing rings that prevent
flow from one side of the sealing rings to the other side of the sealing
rings regardless of flow direction), unidirectional sealing rings (i.e.,
sealing rings that prevent flow from one side of the sealing ring to the
other side of the sealing ring in only one flow direction), V-packing,
and other members for forming seals between components of expandable
reamers 100 known in the art. As a specific, non-limiting example, the
sealing members 132 may comprise D-seal elements, which may comprise
flexible and compressible tubular members having "D" shaped
cross-sections extending circumferentially to form annular members. The
lower end 128 of the travel sleeve 118 may be located below the seal 134,
but above and distanced from the lower end 110 of the housing 102. In the
first operational state, both the first and second ports 126 and 130 may
be located on a common first side (e.g., an upper side) of the sealing
members 132.

[0022] The actuation mechanism of the expandable reamer 100 may comprise a
trigger sleeve 136 located within the internal flow path 122 and
detachably connected to the travel sleeve 118. For example, the trigger
sleeve 136 may be connected to the travel sleeve by detachable hardware
120B, which may comprise, for example, shear screws, shear pins,
exploding bolts, or locking dogs. The trigger sleeve 136 may comprise a
generally cylindrical structure including a sidewall 138 defining an
internal flow bore 140 through which drilling fluid may flow. The trigger
sleeve 136 may comprise at least one trigger port 142 extending through
the sidewall 138 through which drilling fluid may flow from the internal
flow bore 140 to the internal bore 104 and the internal flow path 122 and
vice versa. For example, the trigger sleeve 136 may comprise multiple
trigger ports 142. The trigger ports 142 may be at least substantially
aligned with the second ports 130 of the travel sleeve 118 when the
trigger sleeve 136 is connected to the travel sleeve 118. When it is said
that the trigger ports 142 may be "at least substantially aligned" with
the second ports 130, what is meant is that there is at least some
overlap between the trigger ports 142 and the second ports 130 such that
drilling fluid may flow directly from the internal flow bore 140 of the
trigger sleeve 136, through the trigger and second ports 142 and 130,
into the internal bore 104 of the housing 102. The trigger sleeve 136 may
comprise a second obstruction engagement 144, which may comprise, for
example, a ball seat, a ball trap, a solid seat, an expandable seat, or
other obstruction engagements known in the art, at a lower end 146 of the
trigger sleeve and may be configured to engage with a second obstruction
158 (see FIG. 4) to deactivate the actuation mechanism. A second inner
diameter ID2 of the second obstruction engagement 144 may be greater
than a first inner diameter ID1 of the first obstruction engagement
124, which may enable relatively smaller obstructions to pass through the
second obstruction engagement 144 to engage with the first obstruction
engagement 124.

[0023] The trigger sleeve 136 may be configured to move relative to the
travel sleeve 118 when disconnected from the travel sleeve 118. For
example, the trigger sleeve 136 may be in an unobstructed position when
connected to the travel sleeve, as shown in FIGS. 2 and 3, in which the
trigger sleeve 136 may not obstruct (e.g., may not significantly impede)
drilling fluid flow through the second ports 130 of the travel sleeve 118
because of the at least substantial alignment between the trigger ports
142 and the second ports 130. The trigger sleeve 136 may move to an
obstructed position when disconnected from the travel sleeve 118, as
shown in FIG. 3, in which the sidewall 138 of the trigger sleeve 136 may
obstruct (e.g., may significantly impede or prevent) drilling fluid flow
through the second ports 130 of the travel sleeve 118.

[0024] When in the first operational state, the blades 114 of the
expandable reamer 100 are in the retracted position regardless of
pressure of the drilling fluid within the expandable reamer 100. For
example, locking dogs 150 that may be held in place by the travel sleeve
118 may lock the blades 114 in the retracted position. Such locking of
the blades 114 may retain the blades 114 in the refracted position
regardless of pressure exerted by drilling fluid against any component of
the actuation mechanism. For example, the pressure exerted by the
drilling fluid may be increased or decreased without causing the blades
114 to move from the retracted position to the extended position. The
travel sleeve 118 may be in the first, upper sleeve position in the first
operational state. For example, the detachable hardware 120A may retain
the travel sleeve 118 in the first, upper sleeve position. The trigger
sleeve 136 may be in the unobstructed position in the first operational
state. For example, the detachable hardware 120B may retain the trigger
sleeve 136 in the unobstructed position. Drilling fluid may flow from the
upper end 106 of the housing 102 to the lower end 110 of the housing 102
through the internal bore 104 of the housing 102, the internal flow path
122 of the travel sleeve 118, the internal flow bore 140 of the trigger
sleeve 136, the first, second, and trigger ports 126, 130, and 142. The
drilling fluid may then flow to other, lower components in the drill
string, such as, for example, a downhole motor, a drill collar, and a
pilot bit. Accordingly, the blades 114 may be in the retracted position,
the travel sleeve 118 may be in the first sleeve position, and the
trigger sleeve 136 may be in the unobstructed position when the
expandable reamer 100 is in the first operational state.

[0025] Referring to FIG. 3, a cross-sectional view of the expandable
reamer 100 of FIG. 1 is shown in a second operational state (e.g., a
second mode of operation). Such a second operational state may correspond
to an actuated, subsequent, extendable state, and may reflect a state of
the expandable reamer 100 when drilling the borehole. The actuation
mechanism of the expandable reamer 100 may be actuated to selectively
position the blades 114 in their extended positions.

[0026] To place the expandable reamer 100 in the second operational state,
a first obstruction 152 may be released into the internal bore 104 to
engage with the first obstruction engagement 124 of the travel sleeve
118. The first obstruction 152 may comprise, for example, a ball, a
sphere, an ovoid, or other three-dimensional shape that may be released
into the internal bore 104 to engage with the first obstruction
engagement 124 and at least partially impede flow of drilling fluid out
the lower end 128 of the travel sleeve 118. A first outer diameter
OD1 of the first obstruction 152 may be smaller than the second
inner diameter ID2 of the second obstruction engagement 144 and
larger than the first inner diameter ID1 of the first obstruction
engagement 124, which may enable the first obstruction 152 to pass
through the second obstruction engagement 144 and engage with (e.g.,
become lodged in) the first obstruction engagement 124.

[0027] After engaging with the first obstruction engagement 124, drilling
fluid pressure against the first obstruction 152 may increase as flow out
the lower end 128 of the travel sleeve 118 is at least partially impeded.
The pressure exerted by the drilling fluid may be sufficient to
disconnect the travel sleeve 118 from the housing 102. For example, the
pressure exerted by the drilling fluid may produce a shear stress within
the detachable hardware 120A greater than a shear strength of the
detachable hardware 120A (see FIG. 2) to shear the detachable hardware
120A in embodiments where the detachable hardware 120A comprises shear
pins or shear screws. The pressure exerted by the drilling fluid may then
cause the travel sleeve 118 to move from the first sleeve position to a
second, different sleeve position. For example, the pressure may cause
the travel sleeve 118 to move from a first, upper sleeve position to a
second, lower sleeve position. Movement of the travel sleeve 118 may be
arrested in the second sleeve position by reducing or relieving the
pressure exerted by the drilling fluid, by abutting the lower end 128 of
the travel sleeve 118 against the housing 102 (e.g., against a sleeve
stop 148A of the housing 102), or both. In embodiments where the lower
end 128 of the travel sleeve 118 abuts the sleeve stop 148A, a seal may
not be formed between the travel sleeve 118 and the sleeve stop 148A to
enable drilling fluid to still flow out the first ports 126, into the
internal bore 104, and out of the housing 102. For example, the lower end
128 of the travel sleeve 118, the sleeve stop 148A, or both may comprise
a scalloped edge or a scalloped surface to create a space in which
drilling fluid may flow. The trigger sleeve 136 may remain detachably
connected to the travel sleeve 118 and move with the travel sleeve 118 as
the travel sleeve 118 moves to the second sleeve position.

[0028] When the travel sleeve 118 moves from the first sleeve position to
the second sleeve position, the first ports 126 of the travel sleeve 118
may move from a first side of the sealing members 132 to a second,
opposing side of the sealing members 132. For example, the first ports
126 may move from a first side above the sealing members 132 (see FIG. 2)
to a second side below the sealing members 132. Drilling fluid may then
escape from the internal flow path 122 of the travel sleeve 118, through
the first ports 126, to the internal bore 104 of the housing 102, and out
the lower end 110 of the housing to at least partially relieve the
pressure exerted by the drilling fluid against the first obstruction 152.

[0029] Movement of the travel sleeve 118 from the first sleeve position to
the second sleeve position may release the locking dogs 150, which
previously retained the blades 114 in the retracted position. For
example, the locking dogs 150 may bear against the travel sleeve 118 and
a push sleeve 154 connected to the blades 114 when the travel sleeve 118
is in the first sleeve position. Movement of the travel sleeve 118 to the
second sleeve position may cause the locking dogs to cease bearing
against the travel sleeve 118 and the push sleeve 154, which may enable
the push sleeve 154 to move the blades 114 to the extended position. For
example, drilling fluid flowing in the internal bore 104 of the housing
102 (e.g., drilling fluid flowing outside the travel sleeve 118 in the
internal bore 104 and drilling fluid flowing from the internal flow bore
140 of the trigger sleeve 136, through the trigger ports 142 and the
second ports 130 with which they may be at least substantially aligned,
and into the internal bore 104) may exert a pressure against the push
sleeve 154 to move the push sleeve 154, which may cause the blades 114 to
move correspondingly to the extended position. When in the extended
position, the blades 114 may engage a wall of the borehole to remove
formation material and enlarge the borehole diameter as the expandable
reamer 100 rotates in the borehole.

[0030] The blades 114 may be biased toward the retracted position. For
example, a biasing member 156 (e.g., a spring) may bear against the push
sleeve 154 and the housing 102 to bias the blades 114 toward the
retracted position. The pressure of the drilling fluid may be sufficient
to overcome the bias of the blades 114 toward the refracted position to
move the blades 114 to the extended position. For example, the pressure
exerted by the drilling fluid may produce a force exerted against the
push sleeve 154 greater than a force exerted by the biasing member 156
against the push sleeve 154. The pressure exerted by the drilling fluid
against the push sleeve 154 may move the push sleeve 154, overcome the
bias of the biasing member 156 (e.g., by compressing the biasing member
156), and cause the blades 114 to move to the extended position.

[0031] Increasing or decreasing the pressure exerted by the drilling fluid
may cause the blades 114 to move selectively between the extended
position and the retracted position while the expandable reamer 100 is in
the second operational state. For example, the pressure exerted by the
drilling fluid may be reduced below the pressure exerted by the biasing
member 156, which may cause the biasing member 156 to expand and bear
against the push sleeve 154. The push sleeve 154 may move in response to
the expansion of the biasing member 156, and the blades 114 may be
returned to the retracted position. The pressure exerted by the drilling
fluid may be increased above the pressure exerted by the biasing member
156, which may cause the push sleeve 154 to compress the biasing member
156. The push sleeve 154 may move as it compresses the biasing member
156, and the blades may be returned to the extended position.
Accordingly, the blades 114 may be movable between the extended position
and the retracted position, the travel sleeve 118 may be in the second
sleeve position, and the trigger sleeve 136 may be in the unobstructed
position when the expandable reamer 100 is in the second operational
state.

[0032] Referring to FIG. 4, a cross-sectional view of the expandable
reamer 100 of FIG. 1 is shown in a third operational state (e.g., a third
mode of operation). Such a third operational state may correspond to a
de-activated, final, retracted state, and may reflect a state of the
expandable reamer 100 after reaming the borehole is complete and during
removal of the expandable reamer 100 from the borehole. The actuation
mechanism of the expandable reamer 100 may be deactivated to return the
blades 114 to their retracted positions and to significantly reduce the
likelihood that that blades 114 will move to the extended position
responsive to increases in drilling fluid pressure (e.g., to prevent the
blades 114 from moving to the extended position responsive to increases
in drilling fluid pressure).

[0033] To place the expandable reamer 100 in the third operational state,
a second obstruction 158 may be released into the internal bore 104 to
engage with the second obstruction engagement 144 of the trigger sleeve
136. The second obstruction 158 may comprise, for example, a ball, a
sphere, an ovoid, or other three-dimensional shape that may be released
into the internal bore 104 to engage with the second obstruction
engagement 144 and at least partially impede flow of drilling fluid out
the lower end 146 of the trigger sleeve 136. A second outer diameter
OD2 of the second obstruction 158 may be larger than the second
inner diameter ID2 of the second obstruction engagement 144, which
may cause the second obstruction 158 to engage with (e.g., become lodged
in) the second obstruction engagement 144.

[0034] After engaging with the second obstruction engagement 144, drilling
fluid pressure against the second obstruction 158 may increase as flow
out the lower end 146 of the trigger sleeve 136 is at least partially
impeded. The pressure exerted by the drilling fluid may be sufficient to
disconnect the trigger sleeve 136 from the travel sleeve 118. For
example, the pressure exerted by the drilling fluid may produce a shear
stress within the detachable hardware 120B greater than a shear strength
of the detachable hardware 120B (see FIGS. 2 and 3) to shear the
detachable hardware 120B in embodiments where the detachable hardware
120B comprises shear pins or shear screws. The pressure exerted by the
drilling fluid may then cause the trigger sleeve 136 to move from the
unobstructed position to an obstructed position. For example, the
pressure may cause the trigger sleeve 136 to move from an unobstructed
position in which the trigger ports 142 are at least substantially
aligned with the second ports 130 of the travel sleeve 118 to an
obstructed position in which the sidewall 138 obstructs the second ports
130. Movement of the trigger sleeve 136 may be arrested in the obstructed
position by reducing or relieving the pressure exerted by the drilling
fluid, by abutting the lower end 146 of the trigger sleeve 136 against
the travel sleeve 118 (e.g., against a sleeve stop 148B of the travel
sleeve 118), or both. In embodiments where the lower end 146 of the
trigger sleeve 136 abuts the sleeve stop 148B, a seal may not be formed
between the trigger sleeve 136 and the sleeve stop 148B to enable
drilling fluid to still flow out the trigger ports 142 and the first
ports 126, into the internal bore 104, and out of the housing 102. For
example, the lower end 146 of the trigger sleeve 136, the sleeve stop
148B, or both may comprise a scalloped edge or a scalloped surface to
create a space in which drilling fluid may flow.

[0035] When the trigger sleeve 136 moves from the unobstructed position to
the obstructed position, the trigger ports 142 of the trigger sleeve 136
may move from the first side of the sealing members 132 to the second,
opposing side of the sealing members 132. For example, the trigger ports
142 may move from a first side above the sealing members 132 (see FIGS. 2
and 3) to a second side below the sealing members 132, which may cause
the trigger ports 142 to at least substantially align with the first
ports 126 of the travel sleeve 118. Movement of the trigger ports 142 out
of at least substantial alignment with the second ports 130 of the travel
sleeve 118 may cause the sidewall 138 of the trigger sleeve 136 to
obstruct the second ports 130 (as shown in dashed lines). Drilling fluid
may then escape from the internal flow bore 140, through the trigger
ports 142 and the first ports 126, to the internal bore 104 of the
housing 102, and out the lower end 110 of the housing to at least
partially relieve the pressure exerted by the drilling fluid against the
second obstruction 158. In addition, drilling fluid may be redirected
from flowing through the second ports 130, to the internal flow bore 140,
through the trigger ports 142 and the first ports 126, to the internal
bore 104 of the housing 102, and out the lower end 110 of the housing to
at least partially relieve the pressure exerted by the drilling fluid
against the push sleeve 154. The second obstruction 158 may remain
engaged with the second obstruction engagement 144 during and after
movement of the trigger sleeve 136 because at least substantial alignment
between the trigger ports 142 and the first ports 126 may enable drilling
fluid to be redirected around the second obstruction 158. In some
embodiments, drilling fluid may be expelled from the internal bore 104,
through a relief valve 160, and out to an exterior of the expandable
reamer 100 to at least partially relieve the pressure exerted by the
drilling fluid against the push sleeve 154.

[0036] Reduction in the pressure exerted by the drilling fluid against the
push sleeve 154 may cause the blades to return to the retracted position.
For example, the pressure of the drilling fluid may be less than a
pressure exerted by the biasing member 156 against the push sleeve 154.
The pressure exerted by the biasing member 156 against the push sleeve
154 may move the push sleeve 154 (e.g., by expanding the biasing member
156), overcome the pressure exerted by the drilling fluid, and cause the
blades 114 to move to the retracted position.

[0037] The return of the blades 114 to the retracted position may last for
at least as long as the expandable reamer 100 remains in the borehole.
For example, obstruction of the second ports 130 by the sidewall 138 of
the trigger sleeve 136 may significantly reduce (e.g., eliminate) the
likelihood that increases in pressure exerted by the drilling fluid will
be sufficient to overcome the bias of the biasing member 156 and move the
blades to the extended position. For example, the blades 114 may remain
in the retracted position regardless of increases or decreases in
pressure exerted by the drilling fluid because of the redirection of flow
from the push sleeve 154, which may be caused by blocking transmission of
fluid pressure to the push sleeve 154 by obstructing the second ports 130
with the sidewall 138 of the trigger sleeve 136, through the trigger and
first ports 142 and 126, out into the internal bore 104 of the housing
102. Accordingly, the blades 114 may be in the retracted position, the
travel sleeve 118 may be in the second sleeve position, and the trigger
sleeve 136 may be in the obstructed position when the expandable reamer
100 is in the third operational state.

[0038] While certain illustrative embodiments have been described in
connection with the figures, those of ordinary skill in the art will
recognize and appreciate that embodiments of the invention are not
limited to those embodiments explicitly shown and described herein.
Rather, many additions, deletions, and modifications to the embodiments
described herein may be made without departing from the scope of
embodiments of the invention as hereinafter claimed, including legal
equivalents. In addition, features from one disclosed embodiment may be
combined with features of another disclosed embodiment while still being
encompassed within the scope of embodiments of the invention as
contemplated by the inventor.